Method of anodizing

ABSTRACT

A method of anodizing that is performed in the capacitor case. The anode and a formation cathode are inserted into the capacitor case. The formation cathode includes one or more passageways through which formation electrolyte is transferred to contact the surface of the anode. In one particular implementation, the anode includes several slots and the formation cathodes are plates that are inserted into the slots. One or more valves coupled to formation electrolyte storage tanks storing different electrolytes may be coupled to the formation cathode. A rinsing step can be performed by supplying water through the passageways in the formation cathode. Other implementations anodize outside the capacitor case.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a divisional application of application Ser.No. 11/427,066 to Todd Knowles entitled “Method of Anodizing” which wasfiled on Jun. 28, 2006, now U.S. Pat. No. 8,241,470 the disclosure ofwhich is hereby incorporated herein by reference.

The present application is continuation-in-part application ofapplication Ser. No. 12/608,238 to Todd Knowles entitled “Capacitor”which was filed Oct. 29, 2009, which was a divisional application toearlier application Ser. No. 11/849,198 to Todd Knowles entitled“Capacitor” which was filed Aug. 31, 2007, now U.S. Pat. No. 7,773,367,which was a continuation-in-part application to earlier application Ser.No. 11/380,504 to Todd Knowles entitled “Capacitor” which was filed Apr.27, 2006, now U.S. Pat. No. 7,301,754.

BACKGROUND

1. Technical Field

Aspects of this disclosure relate generally to a method of anodizing acapacitor anode. More specific implementations of an anodizing methodinvolve placing an anode in a capacitor case, placing a formationcathode within the capacitor case and supplying formation electrolytethrough passages in the formation cathode so that the formationelectrolyte is in direct contact with the surface of the anode. In aparticular implementation, the anode includes one or more wells and oneor more formation cathodes are inserted into the wells.

2. Background Art

Generally, an anode of a capacitor is anodized and then inserted intothe capacitor case. Such an anodizing method generally includesconnecting the anode material to a positive terminal of a power supply,connecting a formation cathode to the negative terminal of the powersupply and supplying formation electrolyte. When the circuit is closed,an oxide layer forms on the anode over time. The anode is conventionallyplaced in the capacitor case after this anodizing procedure is complete.

A known method of anodizing includes immersing anodes in electrolyte, asdescribed in U.S. Pat. No. 3,277,553 to Wesolowski (“Wesolowski”), U.S.Pat. No. 3,137,058 to Giacomello (“Giacomello”), U.S. Pat. No. 6,952,339to Knowles, and other patents and publications. In the disclosures ofWesolowski, Giacomello and Knowles, the anodes are placed in thecapacitor assembly after this anodizing method is performed. Thedisclosures of Wesolowski, Giacomello and Knowles are herebyincorporated herein by reference.

A known capacitor assembly includes an anode that surrounds a cathode,as disclosed in U.S. Pat. No. 3,349,295 to Sparkes (“Sparkes”), amongother patents and publications. Sparkes includes a hollow cylindricalanode surrounding a cylindrical cathode pellet core. In the disclosureof Sparkes, the anode is placed in the capacitor container after it isformed and anodized. The disclosure of Sparkes is hereby incorporatedherein by reference.

SUMMARY

In one aspect, this disclosure features continuous or intermitent,direct or indirect, delivery of formation electrolyte to anode materialas an anodizing step. In another aspect, this disclosure features amethod for anodizing after the anode is placed in the capacitor case. Ina particular implementation of the method, the anode includes tantalumanode material defining one or more slots. One or more formationcathodes are disposed in the slots and formation electrolyte isdelivered through passages in the formation cathodes, thereby contactingthe surfaces of the anode where it is desirable to form an oxide. Afteranodizing, the formation cathodes are removed, capacitor cathodes areplaced in the slots and other conventional capacitor assembly steps areperformed.

One advantage of the method disclosed herein is that the anode mayremain in the capacitor case during anodizing, thereby eliminating theneed to transport the anode after the anodization step is completed,which could potentially damage the oxide layer. Another advantage of themethod disclosed herein is that it ensures complete anodization of theporous anode in a relatively short time period. Still another advantageof the method disclosed herein is that a relatively small amount offormation electrolyte is needed since the formation electrolyte isdelivered directly onto the desired surfaces of the anode. Since theamount of formation electrolyte is relatively small, fresh electrolytemay be used every time instead of having a large holding tank offormation electrolyte that may contain contaminants and unwantedby-products.

The method for anodizing may be applied to conventional capacitorshapes, sizes and materials. The method may also be applied tocapacitors that have unconventional shapes, sizes and materials. Themethod may also be applied to the formation of cathodes.

The foregoing and other aspects, features, and advantages will beapparent to those artisans of ordinary skill in the art from theDESCRIPTION and DRAWINGS, and from the CLAIMS.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will hereinafter be described in conjunction with theappended drawings, where like designations denote like elements, and:

FIG. 1 is a cross-sectional view of a system for a method of anodizing,where a portion of the cross-sectional view is taken along sectionalline 1-1 in FIG. 2;

FIG. 2 is a cross-sectional view of a capacitor during the anodizingmethod taken along sectional line 2-2 in FIG. 1;

FIG. 3 is a cross-sectional view of a capacitor after the anodizingmethod taken along sectional line 1-1 in FIG. 2 without the specificpassageways showing;

FIG. 4 is a cross-sectional view of a capacitor after the anodizingmethod with cathode plates deposited in the wells, similar to the viewof FIG. 2 taken during the anodizing method;

FIG. 5 is a front view of a formation cathode;

FIG. 6 is a cross-sectional view of a formation cathode taken alongsectional line 6-6 in FIG. 5;

FIG. 7 is a top-down cross-sectional view, similar to the view of FIG.2, of a capacitor during an anodizing method, the capacitor having arectangular shape;

FIG. 8A is a top-down cross-sectional view, similar to the view of FIG.2, of a capacitor during an anodizing method, the capacitor anode ofFIG. 8B having a cylindrical slot therein taken along sectional line8A-8A; and

FIG. 8B is a cross-sectional view of the capacitor of FIG. 8A takenalong sectional line 8B-8B.

DESCRIPTION

This disclosure, its aspects and implementations are not limited to thespecific components, methods and assembly procedures disclosed herein.Many additional components, methods and assembly procedures known in theart consistent with the intended capacitor, methods and/or assemblyprocedures for a capacitor will become apparent for use withimplementations of the methods of anodizing from this disclosure.Accordingly, for example, although particular hardware is disclosed,such hardware and implementing components may comprise any size, shape,style, type, model, version, measurement, concentration, material,quantity and/or the like as is known in the art for such hardware andimplementing components, consistent with the intended operation ofanodizing and assembling a capacitor. The disclosure is not limited touse of any specific components, provided that the components selectedare consistent with the intended capacitor and/or method of anodizingand assembling a capacitor.

Generally, a method for anodizing comprises providing an anode, placingthe anode in a capacitor case, inserting one or more formation cathodesinto the capacitor case and supplying formation electrolyte throughpassages in the formation cathode(s), thereby forming a continuous oxideon the desired surfaces of the anode. Subsequent to the anodizingprocess, the formation cathodes are removed, capacitor cathodes areinserted into the capacitor case and the assembly of the capacitor iscompleted by performing such steps as filling the capacitor containerwith electrolyte, sealing the capacitor container, and otherconventional capacitor assembly procedures.

In a particular implementation, the anodizing method is shown in FIGS.1-4. In this particular implementation, the shape of the anode isunconventional. However, one of ordinary skill in this art willrecognize that the method can be readily applied to conventional anodeshapes as well as any other desired anode shapes. Shaped anode material10 is placed in a capacitor case 12. The anode material 10 of thisparticular anode implementation includes a plurality of wells in theform of slots 14. Slots are wells that have a length much longer thantheir width (i.e. four to ten times more). The anode material 10 may beshaped in the case or shaped outside the case 12 and later placed in thecase. Formation cathodes 16 are placed in the slots 14. The formationcathodes 16 include passages 18. Formation electrolyte 20 is deliveredto the formation cathodes 16 and through the passages 18 to contact thesurfaces of the slots 14 in the anode material 10. The formationcathodes 16 are connected to the negative terminal 22 of the powersupply 26 while the anode material 10 is connected to the positiveterminal 24 of the power supply 26. When the circuit is closed, an oxidelayer 32 forms on the anode material 10, as shown in FIGS. 3 and 4.

After anodization is complete, the formation cathodes 16 are removed andthe capacitor is assembled. In this particular implementation, cathodeplates 36 are placed in the slots 14 and a suitable separator material35 is placed between the anode 10 and the cathode plates 36. Theremaining steps for assembling the capacitor, such as adding electrolyteand connecting the header to the case 12, are conventional. Thematerials used for the anode material 10, capacitor case 12 andseparator material 35 are all conventional materials known in the art.Components of the method and the capacitor assembly are discussed inmore detail below.

The anodizing method is not limited to anodes that include slots, butcould also be applied to other anode shapes. For example, the anodecould include one or more wells shaped to receive cathodes of othershapes and sizes, such as cylindrical, circular discs, square ortriangle discs, cubes and other shapes, and these wells may extendpartially or entirely through the anode material. The slots may beshaped in the anode during pressing of the powder anode material or bysubsequent removal of the anode material. The formation cathode would beof a shape and material that can be applied to an anodizing methodimplementation discussed herein. Typically, the shape of the formationcathode is substantially the same shape as the cathode that willcomprise the capacitor, though this is not required. Therefore, if theanode material is a hollow cylinder, such as the anode disclosed bySparkes (U.S. Pat. No. 3,349,295, previously incorporated by reference),the formation cathode would be a cylinder that fits within the hollowportion of the anode. If the anode material is a cylinder, such as theanode disclosed by Knowles (U.S. Pat. No. 6,952,339, previouslyincorporated by reference), the formation cathode would be a hollowcylinder that fits around the anode material. The anodizing method couldeasily be adapted for other anode and formation cathode shapes.

The anode 10 is made of a material that is capable of forming adielectric when exposed to the formation electrolyte and anappropriately configured electrical current. In addition, the anode 10material must be compatible with the other capacitor components, such asthe capacitor case, electrolyte and cathode. Examples of appropriateanode materials include, but are not limited to, tantalum, titanium,aluminum and niobium and mixtures thereof. The anode may be shaped bycompressing the powdered metal into a desired anode shape, and sinteringunder a vacuum at high temperatures. The anode may be shaped within thecase or shaped separately and deposited into the case. Otherconventional anode materials and anode-shaping methods could be employedas well. In addition, the anodizing method could be used for anodes ofany size.

The formation cathode may be made of an electrically conductive materialthat is compatible with the formation electrolytes being employed. Forexample, 316 stainless steel can be used as the formation cathodematerial. Less commonly, tantalum may alternatively be used. In oneparticular implementation, shown in FIGS. 5 and 6, the formation cathode16 is formed of two plates 162 and 164 with passageways 18 runningbetween them. The passageways 18 are configured such that formationelectrolyte flows through the passageways 18 into the anode well andcontacts the surface of the anode material 10. The two plates 162 and164 may be welded or otherwise coupled to the flattened or sufficientlysmaller diameter end 166 (shown in phantom in FIG. 5) of a stainlesssteel tube 168 that connects to flexible tubing 167. The passageways 18may also be created by spot welding in a pattern to form channelsbetween the plates 162 and 164. Spot welds 165 are shown in FIG. 6.Although only one entry port for this particular implementation isshown, which then splits into multiple passageways 18, multiple entryports may alternatively be included. The electrolyte may also besupplied to the anode through a separate tube.

Placement of the formation cathode with a dedicated electrolyte supplyflow to the anode being anodized provides additional cooling for theanode oxide layer formation process, removes undesirable bubbles andformation byproducts, and provides fresh electrolyte for the formationprocess. Although particular implementations of the process illustratethe anodes being anodized within their respective capacitor cases, theanode being formed within its final capacitor case is not required.Alternatively, some other formation container may be used and adedicated electrolyte supply to the container holding one or more anodescould be provided. This may equivalently achieve many of the samebenefits as forming the anode within the final capacitor case. It isimportant, however that the container be of a size & shape so that itfits the anodes very closely. Volume in the container in addition tothat occupied by the anode or anodes wastes electrolyte & makes changingelectrolytes and/or rinsing much less efficient.

Thus, distinct from conventional processes where a plurality of anodesare held within a very large tank and electrolyte is passed by them,micro-tanks could be used, each holding one or more anodes (much likethat shown in FIG. 1) with the electrolyte being supplied more or lessdirectly to the individual anode or anodes being formed. In suchsystems, the micro-tank containers would be of a size not more thanabout ten (10) times the total volume of the anodes contained withineach container, and in particular implementations not more than aboutfive (5) times the total volume of the anodes contained within eachcontainer. Use of a significantly smaller tank than is conventionallyused increases the effectiveness of the fluids delivered and theefficiency of fluid delivery. The electrolyte supply for a particularcontainer or case could be configured completely separate from theelectrolyte supplies for the other containers or cases, or could beconfigured as a common electrolyte supply with separate supply lines toeach container or case. They could be separated at the source throughseparate supply lines, or separated at some other point prior toreaching the individual containers. The electrolyte may be supplied bypumping, gravity feed or other method of transferring electrolyte to theanode.

Delivery of the formation electrolyte(s) may be through a continuousflow for each electrolyte or through intermitent flow, such as through aplurality of long or short, but strong, pulses of formation electrolyte.The use of formation electrolyte pulses may assist in purging oldelectrolyte and replacing it with new electrolyte during the anodizingprocess.

The composition and flow rate of the formation electrolyte 20 can becustomized to form an oxide 32 with desired properties and thicknessappropriate to desired capacitor characteristics given the particularcapacitor materials used. Those of ordinary skill in the art ofanodizing are familiar with the parameters of anode formation in asuitable electrolyte and will readily be able to adapt the presentmethods to forming anodes of all types and characteristics. Theformation electrolyte composition is selected such that the oxide isinsoluble therein or dissolves at a slower rate than it forms. In aparticular implementation, the formation electrolyte contains about 10%glycerine, about 0.1% to 1% phosphoric acid, and the remainderde-ionized water, and the continuous flowrate of the formationelectrolyte is between about 0.01 and 5 cc/min per gram of anode weight.When a pulsed flow is used, the flowrate would be approximately doublethat of a continuous flow & would have a duty cycle of between 5% & 70%with a cycle time of between approximately 0.5 seconds to 5 minutes.Other compositions and flowrates of the formation electrolyte could beused, based on the anode material and the desired properties of theoxide to be formed.

The anodizing method is easily adapted to include two or more differentformation electrolyte solutions. Because the electrolyte is suppliedfrom a container or a mixing device, the composition can be easilychanged during the formation process. For example, it may beadvantageous if one were intending to form a high voltage oxide, tobegin with a high conductivity electrolyte which can be made with about1% or more phosphoric acid. However as the voltage across the oxideincreases, it may be desirable to reduce the conductivity so thatmomentary flaws that occur in the oxide as it is being formed do notallow so much current to flow that damaging heat is generated. This iseasily accomplished by switching the electrolyte being supplied to onecontaining a smaller percentage, of perhaps 0.1% phosphoric acid.

The system for using more than one formation electrolyte is shown inFIG. 1. In this particular implementation, three different electrolytesolutions are used in the anodizing method. Each of the three tanks 42,44 and 46 contains a different electrolyte solution. The first formationelectrolyte in tank 42 is utilized by opening the first electrolyteselection valve 52 and operating pump 60, thereby providing the firstformation electrolyte to the formation cathode 16. Similarly, the secondand third formation electrolytes in tanks 44 and 46, respectively, areutilized by opening second and third electrolyte selection valves 54 and56, respectively. The three different electrolyte solutions can be usedone at a time by opening just one of the valves 52, 54 or 56. Acontroller 70 may be included to interface with the power supply 26, thevalves 52, 54, 56, 62, 64, 66, 68, and 74, the operating pump 60, andany other component that may need to be activated, deactivated oradjusted. Although these components of the system may be workedmanually, it is anticipated that computer regulation and manipulation ofthe system will be most convenient. Through computer control, theprocess may be automated such that the anodization process applies theproper voltages, currents and electrolytes for appropriate durationsautomatically without constant attendance. Communication between thecontroller 70 and each of the various components may be accomplishedthrough wired 71 connection or wireless 73 connection.

Alternatively, a combination of two or three of the solutions, ormeasurable mixtures thereof, can be used by simultaneously opening twoor three of the valves 52, 54 and 56. The electrolyte solutions aresupplied through the formation cathode 16 to contact the anode 10surface and then out of the capacitor case 12 and back into tank 42, 44or 46 from which it came by opening an electrolyte return valve 62, 64or 66, respectively. Alternatively, rather than recycle the electrolytesolution, drain valve 68 may be opened, thus allowing the usedelectrolyte solution to drain out of the system. One advantage ofallowing the used electrolyte solution to drain is that only pureelectrolyte solution would then be used in the anodizing method, thuspreventing unwanted by-products and contaminants in the formationelectrolyte. The number of tanks containing different electrolytesolutions is not limited to three. There can be greater or fewer tanks,depending upon the number of desired electrolyte solutions in theanodizing method.

Rinsing with a solvent, such as de-ionized water, can be performedbetween electrolyte solutions or upon completion of anodizing. Themethod and system shown in FIG. 1 can easily be adapted to provide awater rinse step. Clean rinse water is provided to the system throughinlet 72 when valve 74 is open. In the case where it is desired to usenon-compatible electrolytes consecutively during the formation process,thorough rinsing of the first electrolyte from the anode allows thesecond electrolyte to be introduced without concern for interactionbetween them. It is also desirable to perform a thorough rinse after theformation process is complete to remove any excess formation electrolytebefore adding the capacitor electrolyte. A water rinse step could easilybe performed at any point in the anodizing method, including prior tointroducing any formation electrolyte.

In addition to the various liquids mentioned above, the fluids suppliedto the anodes may include gases. For example, hot or dried air may besupplied to the anodes following a rinse step in order to dry them. Orvery hot air having a temperature of about 200° to 450° may be suppliedto the anodes to perform a heat treatment step as is commonly used inthe industry. The use of other gases for these and other purposes mayalso prove beneficial now that it is possible to economically use them.

The power source 26 delivers a current that is sufficient to create anoxide with a desired final formation voltage. The current is usuallybetween about 1 and 100 mA per gram of anode weight. The oxide getsthicker in relation to the amount of current that has flowed andpresents an increasing resistance to the flow of the current. Inaccordance with Ohm's Law, the voltage between the anode connection andthe cathode increases. Final formation voltages could range from as lowas about 3 volts to as high as about 450 volts or even higher. In aparticular implementation, the current setting remains constant untilthe voltage across the oxide is equal to the intended formation voltage.Power sources used for formation have adjustable voltage settings thatthe device will not exceed. This setting is used to set the formationvoltage so that once it is reached, the anodes will be ‘held’ at thatvoltage and not go any higher. In another particular implementation, thecurrent to the anodes is reduced as the voltage increases. In stillother particular implementations, the power source is programmed tofollow a schedule where the current is either turned off or reduced atpoints during the process. Sometimes interim voltages are held in thesame way as the final voltage is held.

After the anodizing method is complete, the remaining steps forcompleting the capacitor are conventional. The formation cathode isremoved and a capacitor cathode is placed in the appropriate place inthe capacitor case. For the implementation shown in FIG. 1, thecapacitor cathode plates 36 are placed in the slots 14 in the anode 10.The capacitor cathodes are made of conventional materials, such astantalum, niobium, carbon, graphite, aluminum, palladium, platinumand/or ruthenium oxide. A conventional separator is placed betweenconventional cathode and anode materials. The capacitor cathode isformed by conventional methods, such as pressing and sintering, shapingfrom homogeneous material and/or coating. In the particularimplementation shown in FIG. 1, the capacitor cathode plates 36 areformed of conventional materials by conventional methods. For example,the plates 36 may include a conductive substrate coated with acapacitive material. The cathode plates 36 may be coupled to a cathodelead which is made accessible from outside the finished capacitor. Thereis no intended implication of a particular number of cathode(s) or anodewell(s) from this disclosure. Any desired number could be used.

The capacitor case is of a conventional size, shape and composition. Inaddition, the methods of forming and assembling the capacitor case areconventional. For example, the capacitor case can be a hollow cylinderopen at one end, such as those disclosed by Knowles (U.S. Pat. No.6,952,339, previously incorporated by reference) and Sparkes. (U.S. Pat.No. 3,349,295, previously incorporated by reference). The capacitor casecan alternatively be rectangular or any other shape disclosed in theprior art. The material of the capacitor case can be the same materialused for the anode. The composition of the capacitor case is compatiblewith the other capacitor components, such as the cathode, anode andelectrolyte. For example, the case material does not react with theformation electrolyte or the electrolyte used in the capacitor assembly,is capable of forming a dielectric and can protect the components withinthe case.

An electrically insulative separator material (not shown) is placedbetween the anode material 10 and the formation cathode 16 to preventelectrical short circuit. Similarly, an electrically insulativeseparator material 34 is placed between the anode 10 and the cathode 36in the final capacitor assembly. However, it may be desirable to includetougher protection as a separator material for the formation cathode 16than for capacitor cathode 36 because the formation cathode 16 will beinserted and removed many times. Both separator materials, however,should be unreactive with the anode and formation cathode or capacitorcathode materials. The separator materials must be unreactive with andinsoluble in the formation electrolyte and/or the capacitor electrolyte.In addition, the separator materials should have a degree of porositysufficient to allow flow therethrough of the formation electrolyteand/or capacitor electrolyte. Illustrative separator materials includewoven and non-woven fabrics of polyolefinic fibers includingpolypropylene and polyethylene or fluoropolymeric fibers includingpolyvinylidene fluoride, polytetrafluoroethelene (Teflon®),polyethylenetetrafluoroethylene, and polyethylenechlorotrifluoroethylenelaminated or superposed with a polyolefinic or fluoropolymericmicroporous film, non-woven glass, glass fiber materials and ceramicmaterials.

The electrolyte used in the capacitor assembly has a conventionalcomposition, but should also be compatible with the other capacitorcomponent materials, such as the anode material, cathode material andthe material of the capacitor case. The electrolyte may be solid orliquid and is put into the capacitor case using conventional processes.For example, a liquid electrolyte may be supplied to the capacitor casethrough a designated lead tube in the header before the hole is sealed.

FIG. 7 illustrates an anode material 80 shaped into a rectangular case82, the anode material 80 having slots 84, therein. A separator material86 is included between the anode material 80 and the formation cathodes88. Passageways 90 are included along the formation cathodes 88. FIGS.8A and 8B illustrate an anode material 92 shaped into a cylindrical case94, the anode material 92 having a cylindrical slot 96 therein. Aseparator material 98 is included between the anode material 92 and theformation cathode 100. Passageways 102 are included along the formationcathode 100. Similar to earlier implementations, formation electrolytemay be supplied to the passages of the formation cathodes to contact thesurfaces of the wells. The formation cathodes are connected to thenegative terminal of the power supply and the anode material isconnected to the positive terminal. When the circuit is closed, an oxidelayer forms on the anode material. After anodization is complete, theformation cathodes are removed and the capacitor is assembled.

These and other shaped anode configurations are shown and described inco-pending, co-owned U.S. patent application Ser. No. 11/380,504, filedon Apr. 27, 2006, entitled “Capacitor.” The disclosure of thisco-pending, co-owned application is hereby incorporated herein by thisreference.

It will be understood that implementations are not limited to thespecific components disclosed herein, as virtually any componentsconsistent with the intended operation of a method and/or systemimplementation for a capacitor may be utilized. Accordingly, forexample, although particular shapes and sizes of capacitor componentsmay be disclosed, such components may comprise any shape, size, style,type model version, class, grade, measurement, concentration, material,weight, quantity, and/or the like consistent with the intended operationof a method and/or system implementation for a capacitor may be used.While the anodizing method for a capacitor anode has been described withan anode and formation cathode of a particular shape with reference tothe drawing figures, it will be understood that the anode and formationcathode shapes are not limited to those depicted. The anode andformation cathode shapes described and depicted in the drawings aregiven as examples and not as limitations.

In places where the description above refers to particularimplementations of a method of anodizing, it should be readily apparentthat a number of modifications may be made without departing from thespirit thereof. The accompanying claims are intended to cover suchmodifications as would fall within the true spirit and scope of thedisclosure set forth in this document. The presently disclosedimplementations are, therefore, to be considered in all respects asillustrative and not restrictive, the scope of the disclosure beingindicated by the appended claims rather than the foregoing description.All changes that come within the meaning and range of equivalency of theclaims are intended to be embraced therein.

The invention claimed is:
 1. A method of anodizing an anode for acapacitor, the method comprising: providing a capacitor case; placinganode material having a plurality of wells within the capacitor case;placing a formation cathode within at least one well of the plurality ofwells within the capacitor case, each well contiguously surrounded on atleast two opposing sides by the anode material; and after the step ofplacing the anode material within the capacitor case, performing ananodizing step including delivering a first formation electrolyte to theanode material by pumping electrolyte directly within at least a firstwell of the plurality of wells.
 2. The method of claim 1, wherein theanodizing step further comprises: delivering the first formationelectrolyte within the at least one well through at least one passage inthe formation cathode.
 3. The method of claim 1, wherein the anodeincludes a cylindrical well among the plurality of wells and theformation cathode is a hollow cylinder configured to surround at least aportion of the anode material.
 4. The method of claim 1, wherein theformation cathode is cylindrical and the anode material is shaped tosurround at least a portion of the formation cathode.
 5. The method ofclaim 1, wherein the anodizing step comprises delivering the firstformation electrolyte through at least one passageway in the formationcathode.
 6. The method of claim 2, wherein the formation cathodecomprises two plates with the at least one passageway therebetween. 7.The method of claim 1, further comprising placing a separator materialbetween the anode material and the formation cathode.
 8. The method ofclaim 2, further comprising placing a separator material between theanode material and the formation cathode.
 9. The method of claim 1,further comprising supplying a second formation electrolyte, differentfrom the first formation electrolyte, within the second well.
 10. Themethod of claim 9, further comprising rinsing with a solvent beforesupplying the second formation electrolyte.
 11. The method of claim 10,wherein the solvent is water.
 12. The method of claim 1, furthercomprising rinsing the anode material with a solvent after performingthe anodizing step.
 13. The method of claim 5, further comprisingdelivering a second formation electrolyte, different from the firstformation electrolyte, through the at least one passageway in theformation cathode.
 14. The method of claim 13, further comprisingrinsing with a solvent between the steps of supplying the firstformation electrolyte and supplying the second formation electrolyte.15. The method of claim 5, further comprising delivering a secondformation electrolyte, different from the first formation electrolyte,within the second well.
 16. The method of claim 15, further comprisingrinsing with a solvent between the steps of delivering the firstformation electrolyte and delivering the second formation electrolyte.17. The method of claim 1, wherein the plurality of wells comprises atleast one slot.
 18. The method of claim 1, further comprising deliveringat least one gas within the at least one well after the step ofdelivering the first formation electrolyte.
 19. The method of claim 18,wherein the at least one gas is a heated gas.
 20. The method of claim 1,wherein delivering the first formation electrolyte to the anode materialcomprises delivering the first formation electrolyte intermittently. 21.The method of claim 20, wherein delivering the first formationelectrolyte intermittently comprises delivering the first formationelectrolyte in a plurality of pulses of formation electrolyte.